Fuel and combustion systems safety: what you don't know can kill you!

Foreword xiii     Preface xv     1 What You Don   t Know Can Kill You 1     1.1 Knowledge Gaps in Operating Fuel Systems and Combustion Equipment / 4     1.2 Managing Fuel Systems and Combustion Equipment Risks / 6     1.3 The Creation of Fuel Systems and Combustion Equipment Codes and Standards / 8     1.4 Fuel System Codes and Standards / 11     1.5 Combustion Equipment Codes and Standards / 12     1.6 Other Widely Recognized Code- and Standards-Related Organizations / 13     1.7 Safety Instrumented Systems and Safety Integrity Levels / 15     1.8 The World of Insurance and Combustion Equipment / 17     1.9 Personal Criminal Liability / 20     Notes and References / 22     2 Combustion Basics 23     2.1 Combustion Defined / 24     2.2 Fuels / 25     2.3 Heat/Ignition / 29     2.4 Oxygen/Air / 29     2.5 Combustion Chemistry / 31     2.6 Environmental Emission Issues / 33     2.7 Basic Burner Design Issues / 35     2.8 Draft Systems / 37     2.9 Understanding and Evaluating Flames / 42     2.10 Fuel/Air Ratio Evaluations / 47     Notes and References / 51     3 Natural Gas Piping Basics 53     3.1 Natural Gas Piping Codes and Standards / 55     3.2 General Industrial Utilities Piping Fundamentals / 56     3.3 Manual Isolation Valves / 57     3.4 Blanks or Blinds / 58     3.5 Steel Pipe Joining Methods / 60     3.6 Fastener Issues: When a Bolt Is Not Simply a Bolt / 63     Notes and References / 64     4 Gas Supply System Issues 65     4.1 Incoming Natural Gas Systems / 66     4.2 Piping Corrosion Protection / 71     4.3 Considerations for Limiting Access to Service Entrances / 77     4.4 Gas Supplies From Digesters and Landfills / 77     4.5 Incoming Propane Service Considerations / 79     Notes and References / 80     5 Gas Piping Repairs and Cleaning 81     5.1 Key Steps to Safe Gas Piping Repairs / 82     5.2 Planning the Project / 83     5.3 Isolation / 84     5.4 Prerepair Venting and Purging of Flammable Gases / 85     5.5 Leak Checking and Pressure Testing / 89     5.6 Postrepair Purge / 91     5.7 Reintroduction of Natural Gas: Startup / 91     5.8 Gas Sampling and Detection / 92     5.9 Nitrogen-Handling Issues to Consider / 95     5.10 The World of Gas Line Cleaning / 101     5.11 NFPA 54: Changes Related to Purging Issues / 110     5.12 Highlights of and Commentary Regarding the New NFPA 56 Standard / 111     Notes and References / 116     6 Understanding Fuel Trains and Combustion Equipment 117     6.1 Fuel Train Components and Their Purpose / 117     6.2 Basic Operations of Fuel Trains / 126     6.3 Oil Firing Systems / 138     6.4 Oven and Furnace Types / 140     Notes and References / 145     7 Understanding Boilers and Their Special Risks 147     7.1 Boiler Incident Statistics / 152     7.2 Boiler Types / 153     7.3 Boiler-Water-Level Safety Devices / 160     7.4 Boiler Pressure Safety Controls / 165     7.5 Safety Relief Valves / 165     7.6 Steam System Piping Special Issues / 168     Notes and References / 171     8 Controlling Combustion Risks: People 173     8.1 Personnel Issues / 175     8.2 Training / 177     8.3 Culture Changes / 179     8.4 Human Layers of Protection Analysis / 183     8.5 Contractor Issues / 192     Notes and References / 195     9 Controlling Combustion Risks: Policies 197     9.1 Policy Commandments for Fuel and Combustion System Safety / 199     9.2 Commandment I / 199     9.3 Commandment II / 201     9.4 Commandment III / 204     9.5 Commandment IV / 208     9.6 Commandment V / 208     9.7 Commandment VI / 209     9.8 Commandment VII / 215     9.9 Commandment VIII / 217     9.10 Commandment IX / 219     9.11 Commandment X / 222     Notes and References / 224     10 Controlling Combustion Risks: Equipment 227     10.1 Controlling Equipment Risks / 229     10.2 Testing of Fuel Train Safety Interlocks / 234     10.3 Rebuilt Safety Controls / 245     10.4 Valve Seat Leakage Tightness Testing / 246     10.5 Refractory and Equipment Outer Skin Problems / 253     Notes and References / 253     11 Global Perspective on Fuel and Combustion System Risks 255     11.1 Global Perspectives on Fuel and Combustion System Risks / 256     11.2 Highlights of the European Combustion World / 257     11.3 Fuel System Risks in Other Countries / 259     11.4 Differences in Types of Systems and Equipment From U.S. to Foreign Operations / 263     11.5 Fuel Issues / 265     Notes and References / 266     12 Business Contingency Planning 269     12.1 Business Interruptions From Fuel and Combustion Systems / 271     12.2 Sparing Philosophies for Components / 276     12.3 Flood and Water Damage / 277     12.4 When There is an Incident / 283     12.5 Conclusion / 285     Notes and References / 286     Appendix: Analysis of Real-Life Stories 287     Index 295